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CHOOSING CORE MATERIALS FOR AEROSPACE APPLICATIONS www.generalplastics.com
CHOOSING CORE
MATERIALS FOR
AEROSPACE APPLICATIONS
www.generalplastics.com
GENERAL PLASTICS MANUFACTURING CO.
General Plastics supplies aerospace and defense manufacturers with build-to-print
flexible foam products and aerospace-grade rigid foam core materials.
WHERE GREAT IDEAS TAKE SHAPE
Established in 1941, General Plastics has been
supplying the global aerospace industry for over
60 years. Among its capabilities:
Sheet stock, machined parts and complex
laminates
Finished parts/build-to-print
On-site R&D, chemists and scale-up
engineers
On-site analytical/testing capability
ISO 9001:2008/AS9100C, NQA-1, MIL-I-
45208A quality systems
ITAR compliant
FST/OSU
Testing Process
Requirements
COMPOSITE MATERIALS
Overview
Industry Trends
FR-3800 FST FOAM
Features and Benefits
Applications
KEY TAKE-AWAYS
Benefits of Composite Core Materials
Reduced weight
Environmental impact
Increased design capabilities
COMPOSITE MATERIAL
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INDUSTRY TRENDS
Source: www.compositesworld.com
45 Years of Composites Evolution (Commercial Transports)
Com
posit
es %
of
Air
fram
e W
eig
ht
Entry Into Service
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PASSENGER JET OPERATING EXPENSES
Fuel
U.S. Gulf Coast Kerosene -Type Jet Fuel Spot Price FOB
35-50% Source: U.S. Energy Information Administration
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FAA specifications
Weight considerations
Drive down costs
Other requirements
TRENDS IN THE AEROSPACE INDUSTRY:
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FST/OSU SPECIFICATION
Fire
Smoke density
Toxicity
Ohio State University
-Heat Release Method
FAA FST/OSU requirements:
65/65/200
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Fire
FST/OSU SPECIFICATION
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Smoke density
FST/OSU SPECIFICATION
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Toxicity
FST-OSU SPECIFICATION
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Ohio State University
-Heat Release Method
FST-OSU SPECIFICATION
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Fire
Smoke density
Toxicity
Ohio State University
-Heat Release Method
FAA FST/OSU requirements:
65/65/200
FST-OSU SPECIFICATION
FAR AND OEM AEROSPACE SPECIFICATIONS
Processing limitations
associated with materials
HOW TO CHOOSE AEROSPACE MATERIALS Things to Consider:
Strength-to-weight ratio
Cost Performance
Safety Requirements
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LAST-A-FOAM® FR-3800 FST
PU-based core material
Halogen-free
Passes FST OSU 65/65/200
specification
Physical properties
congruent with other PU-
based core materials
o 18, 20 pcf densities
meet BMS8-133
https://www.generalplastics.com/fst-3800.html
AEROSPACE MATERIALS CORE MATERIALS COMPARISON
LAST-A-FOAM®
FR-3806 FST PESU PMI PEI End-Grain Balsa
Nominal Density (lb/ft3) 6 5.6 4.7 4.7 6.5
C/S (psi) 144 174 217 160 980
C/M (psi) 4359 11188 NA 14938 325000
Shear Strength (psi) 70 203 188 145 268
Shear Modulus (psi) 1120 2320 4205 4641 15600
Tensile Strength (psi) NA 406 406 240 1000
Tensile Modulus (psi) NA NA 13340 7800 16389
Smoke Density Pass Pass Fail Pass Fail
Total HR Pass Pass Fail Pass Fail
Peak HR Pass Pass Fail Pass Fail
Tg (F) 310 425 350 190 >350
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05
101520253035404550556065
Lab A Lab B Lab C Lab D Lab E
Heat
Rele
ase (6
5/6
5 M
ax)
Test Facility
Heat Release FR-3804 Peak HRR
Total HR
0.0
50.0
100.0
150.0
200.0
Lab A Lab B Lab C Lab D Lab E
Sm
oke D
ensit
y (2
00 D
s M
ax)
Test Facility
Smoke Density FR-3804
(General Plastics)
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05
101520253035404550556065
Lab A Lab B Lab C Lab D Lab E
Heat
Rele
ase (6
5/6
5 M
ax)
Test Facility
Heat Release FR-3804 Peak HRR
Total HR
0.0
50.0
100.0
150.0
200.0
Lab A Lab B Lab C Lab D Lab E
Sm
oke D
ensit
y (2
00 D
s M
ax)
Test Facility
Smoke Density FR-3804
(General Plastics)
|
▶ Passes Fire/Smoke/Toxicity (FST) requirements
▶ Meets OSU 65/65 heat release standards
▶ Alternative to thermoplastics and honeycomb in FST applications
▶ Withstands process temperatures up to 310°F
▶ Range of densities: 3 - 40 pcf
▶ High strength-to-weight ratio from crosslinked structure
▶ Bonds well with composite skins
▶ Resistant to most chemicals and solvents
▶ Will not support fungal growth
▶ No edge-closing or filling needed
FR-3800 FST FOAM OFFERS
OPTIONS FOR USE
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THERMOFORMABLE
▶ Easy processing
▶ Drape / mold forming
▶ Can form all densities
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SANDWICH PANEL LAYUPS
Process using standard vacuum
bag layup techniques
Processing temperatures above
275o F
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POUR IN PLACE PARTS
▶ High levels of detail
▶ Complex shapes without machining
▶ Smooth or textured skin
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HIGH MACHINABILITY
Smooth surface finish
Minimal dust
FST/OSU
FAR flammability specs
Materials testing
COMPOSITE MATERIALS
Weight reduction
Enhanced Performance
Overall cost reduction
FR-3800 FST FOAM
High strength to weight ratio
Low cost material
Versatile processing
Conclusion
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G. Joel Meyer, Ph.D.
Chemistry Laboratory Manager
General Plastics Manufacturing Co.
Q & A
